Maintenance-free door light insert assembly

ABSTRACT

A maintenance-free insert assembly for use with exterior doors of steel or other construction comprising an exterior peripheral frame member including an inwardly extending flange, an interior frame member cooperating with the exterior frame member to retain a pane of glass therebetween, the exterior and interior frame members being secured to the door construction by fastening screws which are driven from the interior side through both the interior frame member and the inwardly extending flange of the exterior frame member to thereby secure the insert assembly in position without employing externally positioned nails, screws, fastening devices, or other construction subject to weather.

United States Patent [151 3,641,721

Martin 1 Feb. 15, 1972 [54] MAINTENANCE-FREE DOOR LIGHT 3,520,085 7/1970 Pond ..52/212 x INSERT ASSEMBLY Primary Examiner-Frank L. Abbott [72] Inventor: Robert I. Martin, Manheim, Pa. Assistant Examiner sam D- Burke [73] Assignee: Rimar Manufacturing, Inc., Manheim, Pa. ArtorneyKarl L- Spivak [22] Filed: Feb. 25, 1970 [57] ABSTRACT [21] Appl' A maintenance-free insert assembly for use with exterior doors of steel or other construction comprising an exterior [52] US. Cl ..52/212, 52/456 peripheral frame member including an inwardly extending [51] Int. Cl flange, an interior frame member cooperating with the exteri- Field of Search 52/204, 211, 212,456;49/171 or frame member to retain a pane of glass therebetween, the exterior and interior frame members being secured to the door [56] References C'ted construction by fastening screws which are driven from the in- UNITED STATES PATENTS terior side through both the interior frame member and the inwardly extending flange of the exterior frame member to 2,871,524 2/1959 thereby secure the insert assembly in position without employ- 2,672,959 3/ 1954 ing externally positioned nails, screws, fastening devices, or 3,404,499 1968 other construction subject to weather. 3,099,865 8/1963 2,791,007 5/1957 3 Claims, 4 Drawing Figures PAIENTEBFEB 15 I972 FIG.

|NVENTOR= ROBERT I. MARTIN FIG. 2

MAINTENANCE-FREE DOOR LIGHT INSERT ASSEMBLY BACKGROUND OF THE INVENTION This invention relates to the general field of building materials and more particularly, is directed to a maintenance-free insert assembly for use in affixing glass lights in exterior doors of metal or other construction.

In an effort to develop longer wearing and structurally sound exterior door construction, engineers, architects, builders and others concerned with the home construction industry have been seeking improved exterior door constructions that are not subject to deficiencies common to wooden doors such as warping, rotting and extensive maintenance costs due to repeated paintings. Most improvements in the art as of this date have proceeded along the path of substituting a metallic door construction to replace the previously almost universally accepted solid exterior wooden door construction.

Metallic doors are usually fabricated of hollow steel and are insulated against the cold by utilizing well-known construction and fabrication techniques. Steel doors as presently produced are factory finished to thereby present a finished product requiring no painting at time of installation and greatly reduced maintenance costs after extended periods of use. In those instances where plain metallic construction is employed, there are no unusual problems and such doors have generally proven beneficial to all concerned. However, in most instances, homeowners are not satisfied with the installation of a simple, plain steel door installation. Such doors offer little aesthetic appeal and are further deficient in that no facility is provided for peering outside to determine exterior weather conditions or the identity of callers. Accordingly, it has become increasingly more popular to provide an opening in the steel door construction to permit the insertion of a glass light which is retained within a peripheral wooden frame. In this manner, the shortcomings above mentioned can be readily overcome.

However, by providing such a glass light within a steel door construction, the former advantages of maintenance free installation were thereby lost inasmuch as the peripheral wooden frame necessary for retaining the glass required painting, maintenance and other attention. Prior workers in the field have found that such wooden frames have a tendency to rot rather quickly in view of the exposed nature of the construction to thereby greatly increase maintenance costs. Additionally, wooden frames as presently provided, are normally not painted at the shop and are delivered to the site in an unpainted condition. The builder then finds himselfin a position wherein the steel door itself has been completely finished at the factory, but that he must employ a door painter notwithstanding simply to finish the small enclosing wooden frame about the glass light. The cost of painting such a small area has resulted in greatly disproportionate painting costs.

SUMMARY OF THE INVENTION The present invention relates to a vinyl plastic window frame construction particularly adaptable to install glass lights within an exterior, weather-resistant door construction. The frame includes an exterior peripheral frame member cooperating with an interior peripheral frame member which connect about an opening provided in an exterior door for installation of a glass light therein. Both the interior frame member and exterior frame member are extruded of pigmented vinyl plastic material, are cut and mitered to the desired size and are designed for weathertight installation within the door without requiring the use of exterior holes, fastenings or other methods of attachment subject to maintenance or leakage.

The interior and exterior frame members include both hard vinyl components for weather resistance and freedom of maintenance and integrally molded soft vinyl sealing components arranged to provide a weathertight, maintenance seal between the frame members and the glass itself.

Additionally, the interior frame member is provided with a peripheral groove spaced from the window glass to receive and retain therein the ends of decorative, plastic, muntin bar assemblies to hold the decorative assemblies in position over the glass. In this manner a single light of glass may be retained in the door construction by use of the interior and exterior vinyl frame members in the interest both of freedom from maintenance and of economy. The peripheral groove facilitates the application of decorative plastic window bar assemblies over the single light of glass to thereby achieve the esthetically pleasing effect of multilight construction but at considerable cost advantage over the former cost of such multilight construction.

It is therefore an object of the present invention to provide an improved maintenance-free window frame suitable for use within an exterior door of the type set forth.

It is another object of the present invention to provide a maintenance-free window frame consisting entirely of components impervious to weather.

It is another object of the present invention to provide a maintenance-free window frame construction that requires no painting or other preventative maintenance.

It is another object ofthe present invention to provide a pair of cooperating inner and outer frame members of design to permit affixing to an exterior door without requiring the use of any exterior fastening devices.

It is another object of the present invention to provide a maintenance-free window frame including an inner frame member, an outer frame member and inwardly extending flange extending the width of the door construction.

It is another object of the present invention to provide a maintenance-free window frame including facilities to receive and retain a decorative window bar construction.

Other objects and a fuller understanding of the invention will be had by referring to the following description and claims of a preferred embodiment thereof, taken in conjunction with the accompanying drawings wherein like reference characters refer to similar parts throughout the several views and in which:

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is an elevational view showing the invention applied to an exterior door.

FIG. 2 is an enlarged, partial, rear elevational view similar to FIG. 1.

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 1 looking in the direction of the arrows.

FIG. 4 is a perspective, exploded view of the frame construction components.

DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of my invention selected for illustration in the drawings and are not intended to define or limit the scope of the invention.

Referring now to the drawings, I show in FIG. 1 a maintenance-free frame [0 applied to a door 12 to retain a single light of glass 14 therein, in secure maintenance-free installation. The present invention finds utility in door constructions suitable for exterior use such as the solid wooden core type or preferably, the hollow metal type wherein the entire door is prefinished at the factory to thereby reduce installation costs at the site to the minimum.

As best seen in FIGS. 1 and 4 the door 12 is provided with an opening 16, which may be rectangular in configuration, to accommodate the glass 14. In the interest of economy, singlelight glass construction is preferably utilized to thereby eliminate the expense of fabrication and installation of individual muntin bars and individual small lights of glass retained therein. The exterior frame member 18 comprises a plurality of decoratively extruded vinyl plastic, pigmented segrnents which are mitered at the corners 20 and joined in wellknown manner to form a unitary frame member of desired dimensions to frame the window opening 16. The exterior frame member 18 includes a decorative, rolled, door retention leg 22 which peripherally outwardly extends from the opening 16 and engages the door 12 in a substantially watertight peripheral junction 24. The door retention leg 22 bifurcates inwardly to form a glass retention leg 26 and an inwardly extending, connection flange 28 which preferably inwardly extends about the window opening 16 the entire width of the door construction.

The connection flange 28 exteriorly and interiorly contacts the periphery 30 of the window opening 16 at 32, 34 to securely position the frame construction within the window opening. Intermediate the exterior window opening peripheral contact 32 and the interior peripheral window opening contact 34, the connection flange 28 arches inwardly to form a glass retaining arch 36 which peripherally contacts and secures the edges 38 of the glass 14. In view ofthe primary use of the invention with exterior doors, the glass section 14 is preferably fabricated of the double layer, insulated glass type comprising an exterior sheet of glass 42, an interior sheet of glass 40 and an insulating airspace 44 therebetween. As best seen in FIG. 3, the exterior glass retention leg 26 terminates inwardly in a plurality of soft vinyl sealing strips 46 which may be integrally formed with and simultaneously extruded with the exterior frame member 18, utilizing well-known plastic extrusion processes. The vinyl sealing strips 46 press against the exterior pane of glass 42 and form a weathertight, maintenancefree connection therewith.

The interior frame member 48 is extruded from pigmented vinyl plastic material similar to the frame member 18 and is fabricated to interiorly, peripherally cover the window opening 16 by cutting the vinyl strips to the size and then sealing the individual segments together to form a strong, continuous peripheral member utilizing cut and sealed miter joints 50. The interior frame member 48 is formed to provide a peripheral, decorative door retention leg 52 which contacts the interior surface of the door 12 in peripheral clamping arrangement at the junction 54.

The interior frame member 48 terminates inwardly in a planar surface 56 which is substantially parallel to the glass 14 which is retained within the frame members. A plurality of soft vinyl seals 58 integrally form with the planar surface 56 and are simultaneously extruded therewith in well-known manner to provide an integral maintenance-free, window-sealing construction. The planar surface 56 terminates downwardly in a depending leg 59 to contact the top of the connection flange 28 which extends from the exterior frame member 18. The depending leg 59 peripherally abuts against the arch 36 to form a sturdy, weathertight connection 61 when the frame members are pulled together as hereinafter more fully set forth.

A peripheral groove 60 recesses in the transition piece between the door retention leg 52 and the planar surface 56 and is fabricated substantially parallel to the plane of the retained window glass 14. The peripheral groove 60 is fabricated to a depth and width suitable to receive the connecting construction which may be a pin, extending from the end of the individual bars 66 of a decorative window grill assembly 64. The window bars 66 are extruded from vinyl plastic material in well-known manner to a decorative shape as desired to simulate the appearance of wooden muntin bars of a decorative, elongate configuration. The plastic bars 66 are sufficiently resilient in accordance with the usual practice to permit flexing the bars medially until the connecting constructions 62 insert within the peripheral groove 60 for decorative grill bar assembly retention purposes. The natural resiliency of the plastic grill bar assembly 64 returns the assembly to the unflexed position to retain the decorative assem bly over the interior of the glass 14 in well-known manner.

As best seen in H6. 3, the interior and exterior frame members 48, 18 affix about the periphery of the opening 16 by employing a plurality of screw fastening members 68 which angularly turn into the door construction. The fastening members 68 turn through the door retention leg 52 of the interior frame member 48, bind the connection flange 28 of the exterior 5 frame member 18 and secure into the periphery 30 of the window opening 16. Thus it is seen that the plurality of fastening members 68 secure both the interior frame member 48 and the exterior frame member 18 without requiring the use of any external holes, pins, screws or other type of securing construction which may interfere with the integrity of the weatherproofing of the window frame construction.

in order to utilize my invention, a window opening 16 is first provided in an exterior door 12, which preferably is fabricated of hollow metallic construction. Interior and exterior frame members 14, 48 are then fabricated of extruded, pigmented, vinyl plastic material of dimensions suitable to fit within the window opening 16 by utilizing respective moisture-resistant, structurally strong, mitered joints 20, 50. A single pane of glass 14 or an insulated glass window construction 40, 42 is then positioned within the window opening 16 and is retained therein by applying the exterior frame member and interior frame member 18, 48 about the periphery of the window opening 16. The exterior and interior soft vinyl seals 46, 58 press about the periphery of the glass construction and provide peripheral, weathertight seat therewith. Fastening members 68 secure the interior and exterior frame members 48, 18 from the interior side of the door 12 by simultaneously securing the door retention leg 52 of the frame member 48 and the inwardly extending connection flange 28 of the exterior frame member 18 to the door construction 70 which defines the window opening 16. When desired, a decorative window bar assembly 64 positions over the interior side of the glass 14 or 40 and end connects into the groove 60 peripherally provided in the interior frame member 48 for decorative grill bar retention purposes.

1 claim:

1. in a maintenance-free window frame for affixing a light of glass within an opening provided in a door having an exterior surface and an interior surface, the combination of A. an outer frame member, a portion of which exteriorly overlies the outer periphery of the opening,

1. the said portion of the outer frame member including a decorative door retention leg which contacts the exterior surface about the opening,

2. the said door retention leg bifurcating inwardly to form a glass retention leg and an inwardly extending, connection flange,

3. the connection flange peripherally overlying the said opening and extending in length a distance substantially equal to the thickness of the door,

4. the glass retention leg contacting a portion of the glass to exteriorly retain the glass within the door opening;

B. an interior frame member, a portion of which interiorly overlies the outer periphery of the opening,

1. said portion of the interior frame member including a decorative door retention leg which contacts the interior surface about the opening,

2. the said interior frame member terminating inwardly in a planar surface which is substantially parallel to the glass, the planar surface carrying first moisture seal means,

3. the said planar surface terminating downwardly in a depending leg,

4. the said leg contacting the top of the connection flange to form a second interior moisture seal means; and

C. fastening means penetrating the door retention leg of the interior frame member and the connection flange of the exterior frame member to simultaneously tie the door retention leg and the connection flange to the door about the said opening therein, the said fastening means terminating in a plane defined by the interior surface of the door.

to retain the window bar assembly in position over the glass.

3. The invention of claim 1 wherein the connection flange arches peripherally inwardly to form a glass retaining arch, the said light of glass being in peripheral contact with the arch t IIK I i 

1. In a maintenance-free window frame for affixing a light of glass within an opening provided in a door having an exterior surface and an interior surface, the combination of A. an outer frame member, a portion of which exteriorly overlies the outer periphery of the opening,
 1. the said portion of the outer frame member including a decorative door retention leg which contacts the exterior surface about the opening,
 2. the said door retention leg bifurcating inwardly to form a glass retention leg and an inwardly extending, connection flange,
 3. the connection flange peripherally overlying the said opening and extending in length a distance substantially equal to the thickness of the door,
 4. the glass retention leg contacting a portion of the glass to exteriorly retain the glass within the door opening; B. an interior frame member, a portion of which interiorly overlies the outer periphery of the opening,
 1. said portion of the interior frame member including a decorative door retention leg which contacts the interior surface about the opening,
 2. the said interior frame member terminating inwardly in a planar surface which is substantially parallel to the glass, the planar surface carrying first moisture seal means,
 3. the said planar surface terminating downwardly in a depending leg,
 4. the said leg contacting the top of the connection flange to form a second interior moisture seal means; and C. fastening means penetrating the door retention leg of the interior frame member and the connection flange of the exterior frame member to simultaneously tie the door retention leg and the connection flange to the door about the said opening therein, the said fastening means terminating in a plane defined by the interior surface of the door.
 2. the said door retention leg bifurcating inwardly to form a glass retention leg and an inwardly extending, connection flange,
 2. the said interior frame member terminating inwardly in a planar surface which is substantially parallel to the glass, the planar surface carrying first moisture seal means,
 2. The invention of claim 1 and a decorative window bar assembly removably connected to the interior frame member, said interior frame member being provided with a peripheral groove and said window bar assembly terminating outwardly in pins of size to fit within and secure to the peripheral groove to retain the window bar assembly in position over the glass.
 3. The invention of claim 1 wherein the connection flange arches peripherally inwardly to form a glass retaining arch, the said light of glass being in peripheral contact with the arch.
 3. the said planar surface terminating downwardly in a depending leg,
 3. the connection flange peripherally overlying the said opening and extending in length a distance substantially equal to the thickness of the door,
 4. the glass retention leg contacting a portion of the glass to exteriorly retain the glass within the door opening; B. an interior frame member, a portion of which interiorly overlies the outer periphery of the opening,
 4. the said leg contacting the top of the connection flange to form a second interior moisture seal means; and C. fastening means penetrating the door retention leg of the interior frame member and the connection flange of the exterior frame member to simultaneously tie the door retention leg and the connection flange to the door about the said opening therein, the said fastening means terminating in a plane defined by the interior surface of the door. 